Match Drilling Tool Gap and Alignment Pin Mechanism
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for drilling holes in composite parts to align with pre-drilled metallic parts are inefficient, often requiring hand-drilling which can damage precision components and is time-consuming, especially in aircraft fuselage assembly where precise alignment is critical and automation is lacking.
Innovation Solution
A match drilling tool with a body featuring a drilling leg and a fixing leg separated by a gap, including a cutter guide opening and an alignment pin opening, allows for precise alignment and drilling of holes in a target part without contacting the pre-drilled part, using an alignment pin to ensure concentricity and a temporary shim to prevent cutter contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hand-drilling is used to drill holes in splice angles to align with T-clip holes, then alignment can be achieved, but the drill may contact the T-clip holes and alter their dimensions, putting T-clips out of specification
Solution Approach 1:
A sacrificial shim is introduced as an intermediary component between the T-clip and the splice angle. The shim has pre-drilled holes that align with the T-clip holes, and the drill bit drills through the shim instead of contacting the T-clip holes directly. This mediator protects the precision T-clip holes from damage while enabling accurate hole alignment in the splice angle.
Solution Approach 2:
The shim is designed with holes that are copies of the T-clip holes, replicating their positions and dimensions. By drilling through the shim to create holes in the splice angle, the precise geometry of the T-clip holes is transferred to the splice angle without directly contacting or damaging the original T-clip holes.
2Extent of automation
If power feed drilling is used to drill through both T-clips and splice angles, then automation is achieved, but it is difficult to gauge whether the guide pin is accurately located prior to drilling
Solution Approach 1:
The T-clip holes are pre-drilled with high precision before assembly, and the shim is pre-drilled to match these holes. This preliminary preparation establishes accurate reference points that guide the power feed drilling operation, ensuring the guide pin is correctly positioned before automated drilling begins, eliminating the need to gauge accuracy during the drilling process.
3Manufacturing precision
If T-clips are removed and replaced when guide pin misalignment occurs, then correct alignment can be achieved, but assembly time is significantly increased
Solution Approach 1:
The shim is designed as a disposable, sacrificial component that is inexpensive to replace. When guide pin misalignment occurs during power feed drilling, instead of removing and replacing expensive T-clips, the operator simply removes the damaged shim and installs a new one. This disposable component absorbs the misalignment error and enables quick correction without time-consuming rework.
4Manufacturing precision
If de-burring and cleaning are performed to correct mis-drilling, then component specifications are restored, but the process is time-consuming
Solution Approach 1:
The sacrificial shim prevents the harmful action of drill contact with T-clip holes in the first place. By providing a protective layer that absorbs drilling errors, the shim eliminates the need for subsequent de-burring and cleaning operations. The preliminary protective measure prevents the creation of burrs and dimensional errors that would otherwise require time-consuming correction.
Data Source
AI summary
A match drilling tool comprising a body comprising a drilling leg and a fixing leg, said drilling leg being separated from said fixing leg by a gap, wherein said drilling leg defines a cutter guide opening, and wherein said fixing leg defines an alignment pin opening, said alignment pin opening being concentric with said cutter guide opening; and an alignment pin slideably received in said alignment pin opening.